CN108348043B - Three-dimensional curing method for two-dimensional printed objects - Google Patents

Abstract

Printing systems are used to selectively print layer materials on surfaces that are initially flat or two-dimensional. After printing the layer material onto the surface, it is exposed to a certain amount of radiation from the radiation source and partially cured. Several layers of material can be placed on top of each other and also partially cured. The flat surface can be reshaped into a non-planar or three-dimensional shape, and the layer material is again exposed to a certain amount of radiation and fully cured.

Description

3D curing method for 2D printed objects

CROSS-REFERENCE TO THE APPLICATION

This application claims priority to US Provisional Patent Application 62/248,594 (Attorney Docket No. 51-4377), filed October 30, 2015, and entitled "Three-Dimensional Curing of aTwo-Dimensional Printed Object," the entire contents of which are Incorporated herein by reference.

technical field

The presented embodiments relate generally to three-dimensional printing systems and methods.

background

Three-dimensional printing systems and methods may be associated with a variety of techniques including fused deposition modeling, electron beam freeform fabrication, selective laser sintering, and other kinds of three-dimensional printing techniques.

Structures formed by 3D printing systems can be used with objects formed by other fabrication techniques. These objects include textile materials used in various articles of footwear and/or clothing.

SUMMARY OF THE INVENTION

This application mainly involves but is not limited to the following aspects:

1) A method of manufacturing an article of footwear, the method comprising:

positioning base material elements in a planar form;

depositing a first layer of material onto the base material element using printing equipment;

partially curing the first layer of material during the first radiation event;

depositing a second layer of material onto the first layer of material using the printing apparatus, the base material element, the first layer of material and the second layer of material forming a layer system;

partially curing the second layer of material during the second radiation event;

reshaping the base material element into a non-planar configuration; and

The layer system is fully cured during the third radiation event.

2) the method according to 1), further comprising:

emitting radiation having a first radiation intensity to the first layer of material during the first radiation event;

emitting radiation having a second radiation intensity to the second layer of material during the second radiation event;

emitting radiation having a third radiation intensity to the layer system during the third radiation event; and

wherein the third radiation intensity is greater than the first radiation intensity, and wherein the third radiation intensity is greater than the second radiation intensity.

3) The method of 2), further comprising converting the first layer of material from a liquid state to a semi-solid state during the first radiation event.

4) The method of 2), further comprising converting the second layer of material from a liquid state to a semi-solid state during the second radiation event.

5) The method of 2), further comprising converting the layer system from a semi-solid state to a solid state during the third radiation event.

6) The method according to 1), wherein:

the layer system includes a first design part and a second design part;

the first design portion has a first cross-sectional area;

the second design portion has a second cross-sectional area; and

The first cross-sectional area is different from the second cross-sectional area.

7) A method of making an article of footwear, the method comprising:

positioning base material elements in a planar form;

depositing a first layer of material onto the base material element using printing equipment;

partially curing the first layer of material during the first radiation event;

depositing a second layer of material onto the first layer of material using the printing apparatus, the base material element, the first layer of material and the second layer of material forming selectively printed design features;

partially curing the second layer of material during the second radiation event;

reshaping the base material element into a non-planar form;

fully curing the selectively printed design features during a third radiation event;

wherein the selectively printed design features include a first design portion and a second design portion;

wherein the first design portion has a first cross-sectional area;

wherein the second design portion has a second cross-sectional area; and

wherein the first cross-sectional area is different from the second cross-sectional area.

8) The method according to 7), further comprising:

emitting radiation having a first radiation intensity to the first layer of material during the first radiation event;

emitting radiation having a second radiation intensity to the second layer of material during the second radiation event;

emitting radiation having a third radiation intensity to the selectively printed design feature during the third radiation event; and

wherein the third radiation intensity is greater than the first radiation intensity, and wherein the third radiation intensity is greater than the second radiation intensity.

9) The method of 7), further comprising converting the first layer of material from a liquid state to a semi-solid state during the first radiation event.

10) The method of 7), further comprising converting the second layer of material from a liquid state to a semi-solid state during the second radiation event.

11) The method of 7), further comprising converting the selectively printed design features from a semi-solid state to a solid state during the third radiation event.

12) The method of 7), further comprising using an ultraviolet light source to emit radiation having the first radiation intensity during the first radiation event.

13) The method of 7), wherein the first layer material is a first material comprising an acrylic resin, and the second layer material is a second material comprising an acrylic resin.

14) A method of making an article of footwear, the method comprising:

positioning base material elements in a planar form;

depositing a first layer of material onto the base material element using printing equipment;

determining a first radiation intensity based on at least a first layer material factor of the first layer material;

partially curing the first layer of material by emitting radiation having the first radiation intensity during a first radiation event;

depositing a second layer of material onto the first layer of material using the printing apparatus, the base material element, the first layer of material and the second layer of material forming a layer system;

determining a second radiation intensity based on at least a second layer material factor of the second layer material;

partially curing the second layer of material by emitting radiation having the second radiation intensity during a second radiation event;

determining a third radiation intensity based on at least a third layer material factor of the layer system;

reshaping the base material element into a non-planar configuration; and

The layer system is fully cured by emitting radiation having the third radiation intensity during a third radiation event.

15) The method of 14), wherein the first layer material factor is the thickness of the first layer material, the second layer material factor is the thickness of the second layer material, and the first layer material factor is the thickness of the first layer material. The three-layer material factor is the thickness of the layer system.

16) The method of 14), wherein the first layer material factor is a curvature level of the first layer material, the second layer material factor is a curvature of the second layer material, and the The third layer material factor is the curvature of the layer system.

17) The method of 14), wherein the first layer material factor is the flexibility of the first layer material, the second layer material factor is the flexibility of the second layer material, and the first layer material factor is the flexibility of the second layer material. The three layer material factor is the flexibility of the layer system, wherein the flexibility of the first layer material and the flexibility of the second layer material refer to the first layer material and the second layer material after partial curing expected flexibility.

18) The method of 14), wherein partially curing the first layer of material further comprises converting the first layer of material from a liquid state to a semi-solid state.

19) The method of 14), wherein partially curing the second layer of material further comprises converting the second layer of material from a liquid state to a semi-solid state.

20) The method of 14), wherein fully curing the layer system further comprises converting the layer system from a semi-solid state to a solid state.

Brief Description of Drawings

Embodiments may be better understood with reference to the following drawings and descriptions. The components in the drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the embodiments. Furthermore, in the drawings, like reference numerals refer to corresponding parts throughout the different views.

Figure 1 is a perspective view of an embodiment of a base material element in planar form.

2 is an embodiment of a general process for forming selectively printed three-dimensional design features on base material elements;

Figures 3-4 illustrate general embodiments and processes considered during a radiation event;

5 is a schematic diagram of the components of the printing system and base material elements that may be used with the printing system;

6 is a schematic diagram of an embodiment of a selectively printed design feature printed onto a base material element;

Figures 7-8 show schematic diagrams of the steps of forming a selectively printed design feature with a three-dimensional structure printed on a base material element;

Figure 9 is an enlarged view of the radiation source transforming a liquid state into a semi-solid state;

10 is a cross-sectional view of layer materials in liquid, semi-solid and solid states;

11 is a schematic diagram of reshaping a base material with selectively printed design features from a planar form to a non-planar form; and

12 is a schematic diagram of a comparison between two processes for base material elements with a layer system, where the base material elements are reshaped from a planar configuration to a non-planar configuration.

Detailed Description

In one aspect, a method of making an article of footwear includes positioning a base material element in a planar configuration. The first layer is deposited onto the base material element using printing equipment. The first layer of material is partially cured during the first radiation event. A second layer of material is deposited onto the first layer of material using printing equipment to form a layer system. The second layer of material is partially cured during the second radiation event. Reshape base material elements into non-planar shapes. The layer system is fully cured during the third radiation event.

In another aspect, a method of making an article of footwear includes positioning a base material element in a planar configuration. The first layer of material is deposited onto the base material element using printing equipment. The first layer of material is partially cured during the first radiation event. A second layer of material is deposited onto the first layer of material using a printing apparatus to form selectively printed design features. The second layer of material is partially cured during the second radiation event. Reshape base material elements into non-planar shapes. The layer system is fully cured during the third radiation event. The selectively printed design features include a first design portion and a second design portion. wherein the first design portion has a first cross-sectional area. wherein the second design portion has a second cross-sectional area. wherein the first cross-sectional area is different from the second cross-sectional area.

In another aspect, a method of making an article of footwear includes positioning a base material element in a planar configuration. The first layer of material is deposited onto the base material element using printing equipment. The first radiation intensity is determined based on at least a first physical property of the first layer material. The first layer of material is partially cured by emitting a first radiation intensity during the first radiation event. A second layer of material is deposited onto the first layer of material using printing equipment to form a layer system. The second radiation intensity is determined based on at least a second physical property of the second layer material. The second layer of material is partially cured by emitting a second radiation intensity during the second radiation event. The third radiation intensity is determined based on at least a third physical property of the layer system. Reshape the base material into a non-planar form. The layer system is fully cured by emitting a third amount of radiation intensity during the third radiation event.

Other systems, methods, features and advantages of the embodiments will be apparent or will become apparent to those of ordinary skill in the art upon review of the following drawings and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description and this summary, be within the scope of the embodiments, and be protected by the accompanying claims.

Figure 1 shows a perspective view of an embodiment of a base material element for printing. As used throughout this disclosure, the base material element or substrate 100 may be associated with apparel or an article of apparel, such as an article of footwear. In this exemplary embodiment, substrate 100 forms an upper of an article of footwear.

In some other embodiments, substrate 100 may be associated with other articles of apparel than footwear. The term "article" is intended to include both articles of footwear and articles of clothing. As used throughout this detailed description and in the claims, the term "article of footwear" and variations thereof include any footwear and any material associated with footwear including an upper, and may also apply to a variety of athletic shoe types Examples include baseball shoes, basketball shoes, cross-training shoes, cycling shoes, football shoes, tennis shoes, soccer shoes, and hiking boots. As used throughout this detailed description and in the claims, the terms "article of footwear" and "footwear" also include types of footwear that are generally considered to be non-athletic, formal or decorative, including dress shoes, casual shoes, Sandals, slippers, boat shoes and work boots.

Although the disclosed embodiments are described in the context of footwear, the disclosed embodiments are equally applicable to any article of apparel, clothing, or equipment. For example, the disclosed embodiments may be applied to, but are not limited to, hats, caps, shirts, sweatshirts, jackets, socks, shorts, trousers, underwear, sports support garments, gloves, Wristbands/armbands, sleeves, headbands, bags, any knitted material, any woven material, any non-woven material and sports equipment such as sports balls, etc. Accordingly, as used throughout this detailed description and in the claims, the term "article of apparel" and variations thereof may refer to any garment or apparel, including any article of footwear as well as brimmed hats, toques, shirts, sweatshirts, jackets , socks, shorts, pants, underwear, sports support garments, gloves, wrist/arm straps, sleeves, headbands, any knitted material, any woven material, any non-woven material.

Referring to Figure 1, the substrate 100 may have a substantially flat or planar geometry. In some embodiments, this planar geometry allows the substrate 100 to be placed on a component of a printing system for printing.

Referring to Figure 2, an embodiment of a general process for forming a three-dimensional object on a base material element is shown. In some embodiments, the three-dimensional object has been selectively printed onto a flat substrate, and the flat substrate is then reshaped into a non-planar object. In some embodiments, some or all of the following steps may be performed by a control unit included within the printing system. In some other embodiments, some or all of these steps may be performed by additional systems or devices associated with the printing system (eg, printing apparatus). Additionally, where the printing device is in electronic communication with the computing system, one or more steps may be performed by a central processing device of the computing system. Additionally, it should be understood that in other embodiments, one or more of the following steps may be optional, or additional steps may be added.

During step 110, the printing apparatus may print an ink layer or other layer material onto the surface of a flat substrate or base material element, or onto a planar portion of an item having a non-planar shape. In some embodiments, an ink layer will be printed on top of the base material elements. In some other embodiments, an ink layer may be printed continuously on top of a previous ink layer, thereby forming a layer system. In some embodiments, the printed ink layer forms design elements on the substrate.

In some embodiments, after the print head has deposited the ink layer on the base material element, the printing system may utilize a device to transform the ink layer and form three-dimensional features, in other words, the ink layer may be converted from a liquid state to a semi-liquid state solid or solid. In some embodiments, converting the ink layer will provide structural properties to the ink layer and/or layer system. In some embodiments, the printing system may use a radiation source to transform or cure the ink layer during a radiation event. As used in this detailed description and in the claims, "curing" and variations thereof include the polymerization or cross-linking of polymeric materials. Curing may be performed by a process including, but not limited to, activation of the additive by ultraviolet radiation, in one embodiment, using a lamp source to emit ultraviolet radiation, sometimes referred to as ultraviolet light. In some other embodiments, the radiation source may be different, but in some other embodiments, other methods may be used to transform the ink layer.

In step 112, the ink layer is partially cured by UV light during the radiation event. For purposes of discussion, a radiation event and variations thereof may refer to exposing a layer material, such as an ink layer, to radiant energy from any radiation source known in the art. During a radiation event, the radiation source may emit a certain physical quantity of radiation, eg a certain intensity of radiation, hereinafter referred to as radiation intensity, thereby affecting the physical properties of the layer material. It will be appreciated that there are various measures of light intensity, including radiant intensity (watts per steradian), luminous intensity (lumens per steradian), irradiance (watts per square meter), and radiance (watts per steradian per square meter) ). Those skilled in the art can select an appropriate measure of intensity or radiation intensity for a given application.

In order to characterize the amount of possible radiation intensity of a radiation source, the radiation intensity is discussed as a percentage of the maximum radiation intensity that the radiation source can emit. Thus, in one embodiment, the possible radiation intensities may range from 0% radiation intensity (no radiation) to 100% radiation intensity (maximum radiation intensity). In some embodiments, the maximum radiation intensity may refer to the maximum radiation intensity achievable by the radiation source or the maximum radiation intensity required to achieve a particular curing effect. In one embodiment, the maximum radiation intensity refers to the amount of radiation required to fully cure the layer material.

In some embodiments, curing the ink layers with UV light can convert them from a liquid state to a semi-solid state, depending on the amount of radiation intensity emitted. In some embodiments, for partial curing, the ink layer may receive less than 50% of the maximum radiation intensity required to convert the ink layer from a liquid state to a solid state. In one embodiment, the amount of radiation intensity emitted by the radiation source used to partially cure the ink layer may range from about 1% to about 50%, typically from about 10% to about 40%. In some embodiments, the ink layer may be partially cured after each layer of ink is deposited by the print head. In some other embodiments, the ink layers may be partially cured when more than one ink layer has been deposited. It should be noted that partial curing of the ink layer occurs when the base material elements are in a substantially flat two-dimensional geometry.

In step 114, after the ink layer has been printed onto the substrate and partially cured by UV light, the substrate is then reshaped into a non-planar or three-dimensional configuration. In some embodiments, the substrate is reshaped to conform to the mold. During reshaping of the substrate, the partially cured ink layer can retain its structural properties and adhere to the surface of the substrate material without any shear stress or deformation. It should be noted that during a radiation event, several factors can be considered when determining the amount of radiation intensity used for curing. In some embodiments, the amount of curvature (ie, the "curvature level") of both the base material element and the layer material may be considered to avoid any shear stress or deformation. In some cases, the amount of thickness of the layer material also needs to be considered. Also in some other embodiments, the flexibility of the layer material needs to be considered during a radiation event. These considerations are explained in more detail below.

In a final step 116, the substrate, now in non-planar form, also includes a plurality of ink layers, also referred to as a layer system. In this step, the layer system is fully cured during another radiation event. During this radiation event, the radiation source may emit a greater amount of radiation than was used to partially cure the ink layer. In one embodiment, the radiation source emits a maximum radiation intensity to fully cure the layer system. Once the base material has been transformed into a non-planar morphology, and the layer system has been fully cured, the result is a three-dimensional non-planar base material with three-dimensionally selectively printed design features without any shear stress or visible structural deformation.

Figures 3 and 4 illustrate a concept of what factors can be considered during a radiation event. FIG. 3 shows an embodiment of a non-planar object having the shape of a sports ball 120 . As shown, in some embodiments, the sports ball 120 may have a printed layer material 122 disposed above the normal surface curvature of the sports ball 120 . In some embodiments, the layer material 122 may have been printed and partially cured on the surface of the sports ball 120 when the sports ball 120 is in a planar configuration. As mentioned above, in order to avoid any shear stress and structural deformation of the layer material 122, the curvature 124 of the layer material 122 and base material elements will be taken into account when the sports ball is transformed into a non-planar configuration. In some embodiments, the flexibility of thickness 126 and layer material 122 will also be considered during a radiation event.

In some embodiments, one skilled in the art will consider the factors discussed above to determine the amount of radiation intensity during a radiation event. Referring to FIG. 4 , a first factor 130 including the curvature of the base material element and layer material, a second factor 132 including the thickness of the layer material and a third factor including the flexibility of the layer material are used in the decision process 134 . As used herein, a curvature level is a measure of the curvature of a layer or base material element, and can include a "flat" level, which is a level with no or zero curvature. Specifically, process 134 uses these factors to determine the amount of radiation intensity used to cure the layer material during a radiation event. This process may be considered a sub-process of either step 112 (partially cure one or more sublayers) or step 116 (fully cure layer material), which have been discussed previously and shown in FIG. 2 .

Each of these factors (eg, factor 130, factor 132, and factor 133) may be referred to as a "layer material factor." These factors generally relate to the macroscopic properties of the layer material, and may be distinguished from, but related to, microscopic properties such as material composition, physical state (eg, liquid or solid), viscosity, etc. Furthermore, as discussed above, each factor can vary depending on the step at which they are considered. For example, to partially cure a layer of material on a flat substrate, the curvature of the base material element (ie, the first factor 130) may refer to the curvature that the layer material will assume after partial curing and reshaping of the base material element. Therefore, if it is known that the base material element will be highly flexible after the layer material is partially cured, the radiation dose should be chosen such that the layer material can bend significantly (without breaking) after the partially cured layer. Conversely, when determining the radiation for final curing, the curvature of the element of base material considered may be the curvature of the element in its current form. Similarly, the thickness of the layer material can be considered as the thickness before (partial or full) curing or the desired thickness of the layer material after the next (partial or full) curing event. Similarly, the flexibility of the layer material can be considered as the current flexibility before (partially or fully) curing or the desired flexibility of the layer material after the next curing event. It can also be seen that the (expected) curvature of the base material element (or the layer material itself) can be related to the (expected) flexibility of the layer material - as higher curvatures may require increased flexibility to limit cracking, cracking or cracking of the layer material. non-plastic deformation. Thus, in some cases, either the flexibility of the layer material or the curvature of the base material element may be considered as a factor in determining the radiation intensity, but not both.

It will be appreciated that during (partial or full) curing, the layer material may undergo a change in physical state or phase. Specifically, curing results in an increase in the viscosity of the material, ultimately resulting in a phase transition from liquid to semi-solid and finally to solid. Thus, factors such as the flexibility of the layer material are generally different for the uncured (liquid) state, the partially cured (semi-solid) state and the fully cured (solid) state of the layer material.

In some embodiments, if the layer material is not provided with an appropriate amount of radiation intensity, the layer material can undergo structural deformation when the base material element is reshaped into a non-planar configuration. It should be understood that providing too much radiation intensity during a radiation event can cause the layer material to be too hard or too brittle to bend. In some other embodiments, an insufficient amount of radiation intensity can cause the layer material not to retain the desired structural shape. It should be noted that, in some embodiments, these factors may be important in determining the type of layer material to place on the base material element. In some embodiments, these factors may be important in determining the location of the layer material on the base material element.

FIG. 5 shows a schematic diagram of an exemplary embodiment of the components of printing system 200 . In some embodiments, printing system 200 may include several components for facilitating printing of objects, such as portions, elements, features, or structures, on substrate 100 . In some embodiments, printing system 200 includes printing device 210 , computing system 220 , and network 230 . These components will be explained in more detail below. For illustrative purposes, only some of the components of printing system 200 are depicted in FIG. 5 and described below. It should be understood that in other embodiments, printing system 200 may include additional devices.

Printing system 200 may utilize various types of printing techniques. These may include, but are not limited to: toner based printing, liquid inkjet printing, solid inkjet printing, dye sublimation printing, inkless printing (including thermal and UV printing), MEMS jet printing technology ( MEMS jet printing technology) and any other printing method. In some cases, printing system 200 may utilize a combination of two or more different printing technologies. The type of printing technique used can vary depending on factors including, but not limited to, the material of the target item, the size and/or geometry of the target item, the desired characteristics of the printed image (e.g. durability, color, ink density) as well as printing speed, printing cost and maintenance requirements.

In some embodiments, printing system 200 includes printing apparatus 210 . In some embodiments, printing apparatus 210 may include features such as housing member 212 , tray 214 , and print head 216 . Housing component 212 may be used to support other components, devices or systems of printing system 200 . In some embodiments, housing member 212 may include features to move substrate 100 during operation. In some embodiments, the shape and size of housing member 212 may vary depending on factors including the desired footprint for printing device 210 , the size and shape of substrate 100 or substrates, the The size and shape of the features and possibly other factors.

In some embodiments, printing apparatus 210 may include a device, such as a table, platform, tray, or the like, for supporting, holding, and/or supporting substrate 100 . In some embodiments, the tray 214 may be used to position the substrate 100 as the layer material is deposited onto the substrate 100 by the print head. In some embodiments, the tray 214 can hold a single substrate 100 . In some other embodiments, the dimensions and dimensions of tray 214 can be designed such that it can hold additional substrates as shown.

Some embodiments may include means to facilitate the formation of selectively printed design features on substrate 100 . In some embodiments, printing apparatus 210 may include means for depositing layer materials onto substrate 100, such as a print head. As noted above, in some embodiments, printing apparatus 210 may include means for applying radiant energy, such as an ultraviolet lamp. In one embodiment, the printing apparatus 210 includes a print head and UV lamps to transform the physical properties of the layer material and form selectively printed design features on the substrate 100 . These devices will be explained in more detail below.

In some embodiments, print head 216 may be used to deposit an ink layer to form selectively printed design features on substrate 100 . As used in this detailed description and in the claims, "selectively printed design features" and variations thereof may refer to depositing a layer of material onto a portion of a surface at selected locations on a base material element to define a The user-selected design, logo or mark at the selected location, and wherein the end result is a design, logo, mark with a three-dimensional structure. The selectively printed design features may also include both single indicia and multiple indicia. In some embodiments, the print head 216 is configured to move within the housing member 212 in a horizontal direction or axis (eg, front-back and/or left-right relative to the housing member 212) and deposit a layer of ink.

Some printing systems may include means for controlling printing apparatus 210 and/or receiving information from printing apparatus 210 . These devices may include computing system 220 and network 230 . As used in this detailed description and in the claims, a "computing system" and variations thereof may refer to the computing resources of a single computer, a portion of the computing resources of a single computer, and/or two or more in communication with each other computer. Any of these resources can be manipulated by one or more human users. In some embodiments, computing system 220 may include one or more servers. In some cases, the print server is primarily responsible for controlling and/or communicating with the printing device 210, while a separate computer such as a desktop, laptop or tablet may facilitate interaction with a user (not shown). Computing system 220 may also include one or more storage devices including, but not limited to, magnetic storage devices, optical storage devices, magneto-optical storage devices, and/or memory (including volatile memory and non-volatile memory). volatile memory).

As shown in FIG. 5, computing system 220 may include a central processing device 222, a visual display component 224 (eg, a monitor or screen), an input device 226 (eg, a keyboard and mouse), and a computer-aided design (eg, computer-aided design) for designing design features. "CAD") represents 228 the software. In at least some embodiments, the CAD representation 228 of the design feature may include not only information about the geometry of the structure, but also information related to the materials required to print the various portions of the design feature.

In some embodiments, computing system 220 may communicate with printing device 210 via network 230 . Network 230 may include any wired or wireless means that facilitates the exchange of information between computing system 220 and printing device 210 . In some embodiments, network 230 may also include various components, such as network interface controllers, repeaters, hubs, bridges, switches, routers, modems, and firewalls. In some cases, network 230 may be a wireless network that facilitates wireless communication between two or more systems, devices, and/or components of printing system 200 . Examples of wireless networks include, but are not limited to, wireless personal area networks (including, for example, Bluetooth), wireless local area networks (including networks utilizing the IEEE 802.11 WLAN standard), wireless mesh networks, mobile device networks, and other kinds of wireless networks. In other cases, network 230 may be a wired network, including networks whose signals are facilitated through twister pair wires, coaxial cables, and optical fibers. In still other cases, a combination of wired and wireless networks and/or connections may be used.

Referring to Figure 6, in some embodiments, printing apparatus 210 may deposit a layer of material to print objects such as selectively printed design features 300 directly onto one or more base material elements. In some embodiments, selectively printed design features 300 may be designed using computing system 220 using some type of CAD software or other kinds of software, as shown in FIG. 5 . The selectively printed design features 300 can then be transformed into information that can be interpreted by the printing device 210 (or an associated print server in communication with the printing device 210). For illustrative purposes, the figures depict some of the components of the printing apparatus 210 separate from other components. Accordingly, the illustrated embodiment is only intended to represent a schematic representation of how the printing apparatus 210 may print the selectively printed design features 300 onto the base material elements.

In some embodiments, selectively printed design features 300 may include a variety of forms including, but not limited to, shapes, alphanumeric characters, and/or other types of indicia. In some embodiments, the selectively printed design features 300 may have structural properties (ie, three-dimensional). In some embodiments, the marks may be arranged in a predetermined pattern. In some other embodiments, the marks may be arranged in a random pattern. In still other embodiments, the markers may be regularly spaced from each other, or not spaced, or irregularly spaced. In an exemplary embodiment, selectively printed design feature 300 includes a plurality of design portions 310 .

As shown in FIG. 6 , the design part 310 may include a first design part 320 , a second design part 330 , a third design part 340 and a fourth design part 350 . In some embodiments, the print head 216 forms the design by depositing a layer of material, such as the ink 302, onto the substrate 100 in several layers along the horizontal or x-axis 362 and/or y-axis 364 in the x-y-z Cartesian coordinate system 360 Section 310. Although the design portions 310 are formed in a relatively two-dimensional manner by the print head 216, in some embodiments, depositing the ink in multiple layers along the x-axis 362 and/or the y-axis 364 results in providing each design portion 310 with Three-dimensional structural properties. In other words, multiple layers along the horizontal axis (x-axis 362 or y-axis 364) by print head 216 result in layers of ink along the vertical axis or z orthogonal to or perpendicular to x-axis 362 or y-axis 364 - Accumulation of axes.

In some embodiments, as ink 302 contacts the surface of substrate 100, subsequent passes of print head 216 may deposit an additional layer of ink 302 on top of the previous layer. In some other cases, the print head 216 may deposit a layer of material on a portion of the substrate 100 that does not have a previous layer of material. In an exemplary embodiment, depositing multiple layers of ink 302 on top of each other may be referred to as a layer system. Subsequent additional layers of ink 302 are deposited along the z-axis to previous layers of ink 302 to provide selectively printed design features 300 with three-dimensional structural properties. In some embodiments, ink 302 may be any type of ink that is curable. In one embodiment, ink 302 is an acrylic resin.

Referring to FIG. 7, a schematic diagram of forming a selectively printed design feature 300 having a three-dimensional structure printed on a two-dimensional or planar substrate 100 is shown. For illustrative purposes, the enlarged views of the following figures depict sequential representations of successive layers of ink 302 being deposited onto substrate 100 by print head 216 . In particular, the enlarged view depicts the design portion 310 as it is formed along the vertical or z-axis 366 .

As shown in FIG. 7 , in the first aspect 400 , the print head 216 deposits the ink 302 onto the substrate 100 in the first pass, producing the first layer 402 . The first layer 402 can be seen to have a first design portion 320 , a second design portion 330 , a third design portion 340 and a fourth design portion 350 . In some embodiments, each design portion has a height along the z-axis 366 and a width along the x-axis. It should also be understood that there may also be a length along the y-axis 364 . It should also be understood that the varying height of each design portion results in each design portion having a different cross-sectional area.

In the second aspect 420 , the print head 216 dispenses another layer of the ink 302 onto the substrate 100 . In some embodiments, printing system 200 may configure printing apparatus 210 such that print head 216 deposits different amounts of ink 302 for each element of the design feature. This results in design portion 310 having a structural height formed along z-axis 366 . Thus, after the printhead 216 has deposited the second layer of ink 302 onto the substrate 100, the first design portion 320 can be seen to have a first design portion height 322, and the second design portion 330 can be seen to have a second design portion height 332 , the third design portion 340 can be seen to have a third design portion height 342 , and the fourth design portion 350 can be seen to have a fourth design portion height 352 . In some embodiments, the first design portion height 322, the second design portion height 332, the third design portion height 342, and the fourth design portion height 352 may all have different values from each other.

Referring to the third aspect 430 , after the last pass through the print head 216 , the resulting layers of ink 302 may be associated with a layer system 432 . As shown, layer system 432 may include first design portion 320 , second design portion 330 , third design portion 340 , and fourth design portion 350 , each having a height along z-axis 366 . In particular, it can be seen along the z-axis 366 that the first design portion height 322 is less than the second design portion height 332, which is seen to be less than the third design portion height 342, which is seen to be less than the third design portion height 342. 342 is in turn smaller than the fourth design portion height 352 . It is to be understood that the number of passes configured by printing system 200 for depositing layers of ink 302 may be varied by those skilled in the art. Note also that the number of passes may depend on a variety of factors including, but not limited to: the size, type, color, and structure of the selectively printed design features, the type of ink used on the substrate, and the The type of material of the substrate.

As discussed above, some embodiments may include means for transforming an ink layer deposited on a substrate. In some embodiments, these devices can convert an ink layer deposited on a substrate from a liquid state to a semi-solid or solid state. In some embodiments, as the layers of ink 302 are deposited by the print head 216, a radiation source may be used to treat the layers. In some embodiments, a lamp source is used to emit radiation and cure the layers of ink 302 . In an exemplary embodiment, the layer of ink 302 deposited onto substrate 100 to form selectively printed design features 300 is treated with an ultraviolet light source. The UV light source may apply a certain amount of UV radiation to the layer. As mentioned earlier, the emission of radiation intensity occurs during a radiation event. The application of ultraviolet radiation to the layer provides structural properties that further define the selectively printed design features 300 .

Referring to Figure 8, it can be seen that the UV light source 500 partially cures the design portion 310 that constitutes the selectively printed design feature 300 during several radiation events. For illustrative purposes, the ultraviolet light source 500 is depicted separate from the other components of the printing apparatus 210 . However, those skilled in the art can contemplate that the ultraviolet light source 500 may be configured in the housing member 212 of the printing apparatus 210 . In particular, housing member 212 may be configured with UV light source 500 such that UV light source 500 may be co-located with print head 216 or adjacent to print head 216 . Accordingly, during operation, the UV light source 500 may apply UV radiation intensity to the layer of ink 302 after the printhead 216 has deposited the layer material.

For clarity, FIGS. 7 and 8 show the deposition of a layer of ink 302 on substrate 100 by print head 216 , the difference being the radiation event by ultraviolet light source 500 . Thus, in FIG. 8 , the first radiation event 520 showing partial UV curing of the design portion 310 may correspond to the first aspect 400 of FIG. 7 . In the first radiation event 520 , the first layer 402 may be transformed from a liquid state to a semi-solid state by the ultraviolet light source 500 . Accordingly, the second radiation event 522 may correspond to the second morphology 420 of FIG. 7 . Furthermore, the third radiation event 524 may correspond to the third modality 430 of FIG. 7 . In some other embodiments, the radiation events of the ultraviolet light source 500 may occur at some other interval.

In some embodiments, after the layer system has been printed by the print head and partially cured by the radiation source, the design feature may have design portions, each design portion having a different cross-sectional area. In some embodiments, the cross-sectional area can vary along the z-axis and the x-axis. In some other embodiments, the cross-sectional area may vary along different axes. Referring to FIG. 8 , in one embodiment, after the third radiation event 524 , the first design portion 320 has a first cross-sectional area 370 along the x-axis 362 and the z-axis 366 . Additionally, the second design portion 330 has a second cross-sectional area 372 along the x-axis 362 and the z-axis 366 . Additionally, the third design portion 340 has a third cross-sectional area 374 along the x-axis 362 and the z-axis 366 . Additionally, the fourth design portion 350 has a fourth cross-sectional area 376 along the x-axis 362 and the z-axis 366 . As shown, the first cross-sectional area 370, the second cross-sectional area 372, the third cross-sectional area 374, and the fourth cross-sectional area 376 are different from each other.

9 and 10 depict embodiments in which design portion 528 is transformed by ultraviolet light source 500 during a radiation event. In some embodiments, as shown in FIG. 9 , after deposition of ink layer 530 , UV light source 500 may be used to partially cure ink layer 530 by emitting radiation intensity 544 . Thus, the radiation intensity 544 will cause the ink layer 530 to polymerize from a liquid state 541 to a partially cured state or semi-solid state 543 . Referring to Figure 10, an enlarged cross-sectional view of the ink layer forming design portion 528 is shown. In the first form 560 , the design portion 528 is in a liquid state 540 . In the second form 562, the ink layer 530 is converted to a partially cured state or semi-solid state 542 after the design portion 528 has been exposed to the radiation intensity 544 from the ultraviolet light source 500 during the first radiation event. In the third aspect 564, the ultraviolet light source 500 can emit the maximum amount of radiation intensity to transition the ink layer 530 from the semi-solid 542 state to the fully cured state or solid state 546 during another radiation event, and thus design portion 528 From a semi-solid 542 state to a fully cured state or solid 546 state.

In some embodiments, the base material elements may be reshaped after the printing system has completed printing the selectively printed design features on the planar base material elements, and after the selectively printed design features have been partially cured by the radiation source is non-planar. In some embodiments, placing the substrate on the mold can transform the substrate from a planar shape to a non-planar object.

Referring to FIG. 11, in one embodiment, after the selectively printed design feature 300 has been placed on the substrate 100 and partially cured by the UV light source 500, it is reshaped into a non-planar form and placed into a non-planar mold 600 superior. The design elements 310 of the selectively printed design features 300 will then undergo full UV curing by the UV light source 500 during the radiation event. In some embodiments, ultraviolet light source 500 will emit radiation intensity 610 to cure first design portion 320 , second design portion 330 , third design portion 340 , and fourth design portion 350 . In some embodiments, the amount of radiation intensity from light source 500 during this radiation event may be greater than the amount of previous radiation intensity emitted during previous radiation events. The result is an upper 620 of an article of footwear having selectively printed design features 300 having design portions 310 with three-dimensional structures.

In some embodiments, design portions 310 located on upper 620 may have different cross-sectional areas, as shown in the enlarged view and previously discussed with respect to FIGS. 7 and 8 . Therefore, after complete curing by the UV light source 500 , the first design portion 320 having the first cross-sectional area 370 , the second design portion 330 having the second cross-sectional area 372 , the third design having the third cross-sectional area 374 Portion 340, as well as fourth design portion 350 having fourth cross-sectional area 376, will all have different cross-sectional areas along x-axis 362 and z-axis 366 from each other, as shown in the enlarged views of FIGS. 7 and 8. shown.

In some other embodiments, a second selectively printed design feature 650 may also be placed on upper 620 . In some embodiments, the second selectively printed design feature 650 will be different from the design element 310 . In some embodiments, the second selectively printed design feature 650 may be printed while the substrate is in a planar configuration. In some embodiments, the second selectively printed design feature 650 may include several printed layers of material. Still in some other cases, although illustrated as a unitary element, the second selectively printed design feature 650 may include different local cross-sectional areas along the horizontal and vertical axes. In one embodiment, the second selectively printed design features are simultaneously printed by print head 216 during printing of design element 310 . It should be understood that the second selectively printed design features 650 may be partially cured by the UV light source 500 after each layer of material is placed on the substrate. It is further understood that when the substrate is reshaped into a non-planar configuration, the second selectively printed design feature 650 will undergo full curing by the UV light source.

In some embodiments, this method of partially curing the printed layer material on a planar base material element and then fully curing the printed layer material after the base material element is reshaped into a non-planar configuration, improves the structure of the layer material In nature, in contrast, methods of fully curing the layer material and then transforming the base material elements into a non-planar morphology can result in three-dimensional structures that contain structural deformations and stresses. Referring to Figure 12, a side-by-side comparison of the exemplary method 700 and the previous method 750 is shown.

In the first aspect 702 of the exemplary method 700 , the layer system 710 has been selectively printed onto a planar base material element 714 . In some embodiments, base material element 714 may be associated with an article of apparel. In some embodiments, the radiation source 716 will emit a first amount of radiation intensity 718 during the first radiation event and partially cure the layers as they are deposited on the base material element 714 . Layer system 710 is formed by depositing one layer on top of another, as described above. In some embodiments, partial curing will convert layer system 710 from a liquid state to a semi-solid state. Additionally, in some cases, partial curing also bonds layer system 710 to base material element 714 . In the second configuration 704, the base material element 714 is reshaped into a non-planar configuration and placed on the mold 722 after the layer system 710 has been partially cured. Then, in the third configuration 706, when the base material element 714 is in the non-planar configuration, the radiation source 716 will emit the maximum amount of radiation intensity 724 during a subsequent radiation event to fully cure the layer system 710. In some embodiments, the radiation intensity 724 passing through the radiation source 716 will cause the structural properties of the layer system 710 to change from semi-solid to solid. Furthermore, full curing will improve the adhesion between layer system 710 and base material element 714 . Thus, the example method 700 results in no shear stress or strain between the layer system 710 and the base material element 714 . As shown in the fourth aspect 708, after the layer system 710 has fully cured and the base material element 714 is removed from the mold 722, the resulting article 730 is free of any internal or external deformation and distortion.

Compared to the exemplary method 700, the previous method 750 may result in visible stresses and strains in articles with design features. In the first aspect 752 of the previous method 750, the design features including the layer system 760 have been printed layer by layer onto the substrate 764 in a planar configuration. However, in place of the partially cured layer system 760, the previous method 750 would use the radiation source 766 to emit the maximum amount of radiation intensity 784 during the radiation event and fully cure the layer system 760. During this radiation event, the maximum amount of radiation intensity 784 transforms the layer system 760 from a liquid state to a solid state. In the second configuration 754 , the substrate 764 is reshaped from a planar configuration to a non-planar configuration and placed onto the mold 782 . In the third configuration 756, shear stress and structural deformation 786 may occur during the process of reshaping and placing the substrate 764 on the mold 782 because the layer system 760 is fully cured and thus in a solid state. In the fourth configuration 758 , the substrate 764 is removed from the mold 782 . In this configuration, the layer system includes shear stress and visible structural deformation 786 as compared to layer system 710 of example method 700 .

The embodiment shown in the figures depicts UV lamp curing. It will be appreciated, however, that in some other embodiments, other curing methods may be used. In another embodiment, for example, electron beam curing can be used. In some cases, a robotic arm may be used to move the object relative to the electron beam source for curing (or alternatively, the electron beam source may be mounted on the robotic arm and the object held in place).

While various embodiments have been described, this description is intended to be illustrative and not restrictive, and many more embodiments within the scope of the embodiments will be apparent to those of ordinary skill in the art and implementation is possible. Any feature of any embodiment may be used in combination with or in place of any other feature or element of any other embodiment, unless specifically limited. Accordingly, the embodiments are not to be limited except in light of the appended claims and their equivalents. Furthermore, various modifications and changes may be made within the scope of the appended claims.

Claims (18)

1. A method of three-dimensional curing of a two-dimensional printed object, the method comprising:

positioning a base material element into a planar form;

depositing a first layer of material onto the base material element using a printing apparatus;

partially curing the first layer material by emitting radiation having a first radiation intensity to the first layer material during a first radiation event;

depositing a second layer of material onto the first layer of material using the printing apparatus, the base material element, the first layer of material, and the second layer of material forming a layer system;

partially curing the second layer of material by emitting radiation having a second radiation intensity to the second layer of material during a second radiation event;

reforming the base material element into a non-planar form; and

fully curing the layer system comprising the base material elements reshaped to the non-planar topography by emitting radiation having a third radiation intensity to the layer system comprising the base material elements reshaped to the non-planar topography during a third radiation event, wherein the third radiation intensity is greater than the first radiation intensity and the second radiation intensity.

2. The method for three-dimensional curing of a two-dimensional printed object according to claim 1, further comprising transforming the first layer of material from a liquid state to a semi-solid state during the first radiation event.

3. The method for three-dimensional curing of a two-dimensional printed object according to claim 1 or claim 2, further comprising transforming the second layer material from a liquid state to a semi-solid state during the second radiation event.

4. A method of three-dimensional curing of a two-dimensional printed object according to claim 1 or claim 2, further comprising transforming the layer system from a semi-solid state to a solid state during the third radiation event.

5. The method for three-dimensional curing of a two-dimensional printed object according to claim 1 or claim 2, wherein:

the layer system comprises a first design portion and a second design portion;

the first design portion has a first cross-sectional area;

the second design portion has a second cross-sectional area; and is

The first cross-sectional area is different from the second cross-sectional area.

6. A method of three-dimensional curing of a two-dimensional printed object, the method comprising:

positioning a base material element into a planar form;

depositing a first layer of material onto the base material element using a printing apparatus;

partially curing the first layer of material during a first radiation event having a first radiation intensity;

depositing a second layer of material onto the first layer of material using the printing apparatus, the base material element, the first layer of material, and the second layer of material forming a selectively printed design feature;

partially curing the second layer of material during a second radiation event having a second radiation intensity;

reforming the base material element into a non-planar form; and

fully curing the selectively printed design features including the base material element reformed into the non-planar form during a third radiation event having a third radiation intensity that is greater than the first radiation intensity and the second radiation intensity;

wherein the selectively printed design feature comprises a first design portion and a second design portion;

wherein the first design portion has a first cross-sectional area;

wherein the second design portion has a second cross-sectional area; and is

Wherein the first cross-sectional area is different from the second cross-sectional area.

7. The method for three-dimensional curing of a two-dimensional printed object according to claim 6, further comprising transforming the first layer of material from a liquid state to a semi-solid state during the first radiation event.

8. The method for three-dimensional curing of a two-dimensional printed object according to claim 6, further comprising transforming the second layer material from a liquid state to a semi-solid state during the second radiation event.

9. The method for three-dimensional curing of a two-dimensional printed object according to claim 6, further comprising transforming the selectively printed design feature from a semi-solid state to a solid state during the third radiation event.

10. The method of three-dimensional curing of a two-dimensional printed object according to claim 6, further comprising emitting radiation having the first radiation intensity using an ultraviolet light source during the first radiation event.

11. The method for three-dimensional curing of a two-dimensional printed object according to claim 6, wherein the first layer material is a first material comprising acrylic and the second layer material is a second material comprising acrylic.

12. A method of three-dimensional curing of a two-dimensional printed object, the method comprising:

positioning a base material element into a planar form;

depositing a first layer of material onto the base material element using a printing apparatus;

determining a first radiation intensity based on at least a first layer material factor of the first layer material;

partially curing the first layer of material by emitting radiation having the first radiation intensity during a first radiation event;

depositing a second layer of material onto the first layer of material using the printing apparatus, the base material element, the first layer of material, and the second layer of material forming a layer system;

determining a second radiation intensity based on at least a second layer material factor of the second layer material;

partially curing the second layer of material by emitting radiation having the second radiation intensity during a second radiation event;

determining a third radiation intensity based on at least a third layer material factor of the layer system;

reforming the base material element into a non-planar form; and

fully curing the layer system including the base material element reshaped into the non-planar form by emitting radiation having the third radiation intensity during a third radiation event.

13. The method for three-dimensional curing of a two-dimensional printed object according to claim 12, wherein the first layer material factor is a thickness of the first layer material, the second layer material factor is a thickness of the second layer material, and the third layer material factor is a thickness of the layer system.

14. The method for three-dimensional curing of a two-dimensional printed object according to claim 12, wherein the first layer material factor is a level of curvature of the first layer material, the second layer material factor is a curvature of the second layer material, and the third layer material factor is a curvature of the layer system.

15. The three-dimensional curing method of a two-dimensional printed object according to claim 12, wherein the first layer material factor is a flexibility of the first layer material, the second layer material factor is a flexibility of the second layer material, and the third layer material factor is a flexibility of the layer system, wherein the flexibility of the first layer material and the flexibility of the second layer material refer to a desired flexibility of the first layer material and the second layer material after partial curing.

16. The three-dimensional curing method of a two-dimensional printed object according to any of claims 12-15, wherein partially curing the first layer material further comprises transforming the first layer material from a liquid state to a semi-solid state.

17. The three-dimensional curing method of a two-dimensional printed object according to any of claims 12-15, wherein partially curing the second layer material further comprises transforming the second layer material from a liquid state to a semi-solid state.

18. The three-dimensional curing method of a two-dimensional printed object according to any of the claims 12-15, wherein fully curing the layer system further comprises transforming the layer system from a semi-solid state to a solid state.

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